System for automatically handling setters filled with ceramic tile

ABSTRACT

The present invention is directed to a system for continuously processing unfired, glazed or green ceramic tile during the curing thereof. More specifically, the system automatically handles setters containing the tiles and according to the present invention comprises a loading station where freshly painted ceramic tiles are loaded into setters or saggers, a loading conveyor upon which the loaded setters originally embark, a load/unload transfer carriage which simultaneously transfers a course of setters loaded with green tiles from the conveyor onto a first, empty kiln car for transportation to a kiln and a course of setters loaded with fired tiles from a second, loaded kiln car back onto said conveyor, a flipover device which tilts the setters to a horizontal position, whereupon the tiles slide out by gravity, and a setter-turning device which returns the setters to their original upright position on the conveyor belt. The aforementioned elements are integrated into a closed loop system operated by a series of limit switches and photoelectric cells.

United States Patent [72] Inventor John J. Brown, Jr.

Siler City, NC. [21] App]. No. 816,243 [22] Filed Apr. 15,1969 [45]Patented Mar. 23, 1971 v [73] Assignee Forrest Paschal Machinery CompanySiler City, N .C.

[54] SYSTEM FOR AUTOMATICALLY HANDLING SETTERS FILLED WITH CERAMIC TILE15 Claims, 15 Drawing Figs.

11.8. CI V 2 5/2, 198/1 9, 214/6A, [51] Int. Cl. B2 8b /00 B65g /52, Bg60/00 [50] Field of Search 25/2;

198/19, 214/6, (Inquired) [56] References Cited UNITED STATES PATENTS3,412,439 11/1968 Baker 25/1 I 3,474,917 10/1969 Pearne et al. 25/2X3,517,831 6/1970 Hahn Primary Examiner-Robert D, Baldwin Att0rney Hunt,Heard & Rhodes ABSTRACT: The present invention is directed to a systemfor continuously processing unfired, glazed or green ceramic tile duringthe curing thereof. More specifically, the system automatically handlessetters containing the tiles and according to the present inventioncomprises a loading station where freshly painted ceramic tiles areloaded into setters or saggers, a loading conveyor upon which the loadedsetters originally embark, a load/unload transfer carriage whichsimultaneously transfers a course of setters loaded with green tilesfrom the conveyor onto a first, empty kiln car for transportation to akiln and a course of setters loaded with fired tiles from a second,loaded kiln car back onto said conveyor, a flipover device which tiltsthe setters to a horizontal position, whereupen the tiles slide out bygravity, and a setter-turning device which returns the setters to theiroriginal upright position on the conveyor belt. The aforementionedelements are integrated into a closed loop system operated by a seriesof limit switches and photoelectric cells.

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sum 13 0F 15 U Q iM-%\A 22Ol4-4-O VAC Q L2 DISCONNECT Tl av OTHERS SS WWIRE FOR 220 V. A.C. FUI 0FF\ ,onn VAC VACUUM PUMPI VACUUM PUMPS VACUUMPUMP 2 FU 2 A 0FF\ /ON 5 6 POWER UNIT E W- POWER UNIT START -P8l 1 Pa2 eLRl LRI TDRI I L Q FULL CR3 LSI3 la 20 H PO -WALL. EXCEPT PADS INCH a su LSI SETTER BELT w OFF START PULLER sa DELAY l6 l2 QILATCH UP LS6PUSHER UNLATCH LR3 EMPTY TURNER BACK L812 I3 L825 14 Lszo 0% 25UFRATCHET UP FLIP ovER INDEX BELT ml! 06 RELAY Lgg 22 LANDING PADS L0H;VACUUM LR3 DOWN T 98 m '99 LS5] w CR3 99 ms TRANSFERS LR3 LS4O as 24boown TRANSFER DOWN ag LANDING 25 cRs j 2} PADS o |:p-o-| I a r--- 1L826 TRANSFERS UP 28 l LANDING fi' B B 6% I PADS up 29 CR3 LR3 3| UP ILR3 ao H TRANsr H 3g FERS 1| I DOWN SETTER FULLER 9 A a c o E INVENTOR.FIG. 14A JOHN J- BROWN JR.

PATENTEU MAR 2 3 IBYI SHEET 15 F INCH BELT 9 FULL I LOAD PAD 2 2A eaLSIB e9 LSI4 ,-o-] |-o-o- Ii-0; L |,3,6,e,u,|3

CR2 70 I LOAD HOIST O-| H up 3,8,I3 3A 3B 12 1 up I n l/UNLOAD HOIST JDOWN 5A 5B 77 Y K VACUUM a UNLOAD 3,8,I3

PAD UNLOAD L 78 vsz CR6 go 79 E LOADED UNLOADED HOIST HOIST cnz CR6 v32caa one up up N we LS|9 a2 IOA I08 83 X3 XA 5A 58 -0 o-oo-{|oo o-o- :)-ol368lll3 s F 81 a5 BAHBB' gi I TEST AUTO L$ c0cAR 86 9A 9 STEP sw I MODEcomm a? |2A I28 0 0 o I o I P83 ALL BUT PROGRAM ADV 5 IO I8 I I Q TESTCAR PUSHER o -o 2TRA-sF:-:Rs AND INCH BELT B8 33 0-0{ 3SETTER PULLER oo4 FLIP OVER DEVICE TEST -l 5 PUSHER 0o- SELECTOR s CARRIAGE TO KILN CAR0o- 7 CARRIAGE T0 men BELT a HOISTS UP 7 9 HOISTS DOWN o- |o vacuum T0LOAD 7 u VACUUM TO UNLOAD I2 CAR PUSHER RETURN 9 L527 STOP INCH BELT cmENABLE L828 INCH BELT 9| L529 g g cm ENABLE L830 13A I38 92 W A-I 4, l14A FCLMB 93 M |5A I I58 M -04. one LRI MSI "IOI PROGRAM as STATUS o LowINVENTOR. as 97 0 TERNAL AR JOHN J- BROWN JR- F R EX AL M FOR VACUUMFAILURE BY 60- CARRIAGE OVER Filth. AUTGMATECALILY HANDILHNG SETTEMHELLER WllTE-ii CERAMW TIILE SUMMARY OF THE llNVENTION The presentinvention comprises preferably a closed, rectangular, conveyor loop, oneside of the loop being at a lower elevation than the other three sides.The lower conveyor, called the loading index conveyor, presents a singlefile of empty setters or saggers, which move into position adjacent oneof two tile loading machines positioned adjacent the loading index belt.The loaded setters are then carried to one end of the loading indexconveyor where they are transferred onto the second side of the conveyorloop called the inching conveyor.

A transfer device lifts the setters two at a time from the loading indexconveyor up onto the inching conveyor which is at a higher elevation,whereupon the setters proceed to a loading area. When a course or layeris formed in the loading area, a first pickup head on a load/unloadtransfer carriage lifts the setters and transfers them to a kiln carwhich has been moved to a position adjacent the loading area of saidinching conveyor. As the first pickup head releases the setterscontaining the green tiles, a second pickup head at the other end of thetransfer carriage lifts a course or layer of setters containing firedtiles from a kiln car which has returned from the kiln and transfers itback to an unloading area on the inching conveyor with the returnmovement of the transfer carriage. This cycle is repeated until aprescribed number of layers or courses of setters are deposited upon theempty kiln car and the same number of courses are removed from theloaded kiln car returning from the kiln.

The setters containing cured tiles are then transferred to the thirdside of the conveyor loop called an unloading index conveyor. Thesetters proceed along the unloading index belt to the other endwhereupon a hydraulically operated setter pusher pushes a pair ofsetters over onto a flipover device. The flipover device then turns thetwo setters 90 into a facedown position on the fourth side of theconveyor loop called a V- belt conveyor.

As the setters pass over a gap or slot in the V-belt conveyor, the tilesdrop from their respective slots in the setter into a suitablereceptacle. The setters then proceed down the V-belt conveyor to acleaning station and on to the end of the V-belt conveyor.

Another transfer device called an empty setter puller/turner comprises aseries of horizontally disposed suction heads which grasp the setters,pull them onto a hinged plate, whereupon they are rotated 90 to anupright position on the first side of the conveyor loop whereupon theyreturn to be reloaded.

it is therefore an object of this invention to provide a system forautomatically handling setters filled with green ceramic tiles around aclosed loop conveyor whereby the setters are filled, loaded onto andunloaded from kiln cars, emptied, cleaned, and returned to theiroriginal loading position.

It is another object of this invention to provide a closed loop systemof the type described wherein setters filed with green ceramic tiles aretransported to a kiln and returned more quickly and efficiently than hasheretofore been achieved.

it is still a further object of this invention to provide a closed loopsystem of the type described wherein setters filled with green ceramictiles are delivered to a kiln and returned quickly and efficiently, yetwith the care and delicacy required to eliminate breakage of the tiles.

it is yet another and more specific object of the invention to provide aclosed loop system of the type described that includes a setter loader,a load/unload transfer carriage, a flipover device for emptying thesetters, a resetting device for returning the setters to an uprightposition, and a series of conveyors connecting such devices.

Further objects and advantages within the scope of this invention suchas relate to arrangement, operation and function of the related elementsof the structure, and various details of the construction will beapparent from a consideration of the specification and drawings of theillustrated embodiment of the invention.

The operation of the machine and objects of the invention may be betterunderstood in connection with a complete description which will be givenin connection with the drawings wherein:

F IG. i is a plan view of the system for handling setters filled withgreen ceramic tiles according to the present invention;

FIG. 2 is a perspective view of the load/unload transfer carriage withthe remainder of the system broken away;

FIG. 3 is an enlarged perspective view illustrating the carriage uponwhich the pickup heads are mounted;

P16. 4 is a plan view of the load/unload transfer carriage illustratedin FIG. 2;

FIG. 5 is an elevation view of the transfer carriage illustrated in FIG.2;

FIG. 6 is an end view of the transfer carriage illustrated in FIG. 2; J

7 is an enlarged perspective view with parts broken away of the setterpusher/flipover device;

FIG. 8 is a plan view of the setter pusher/flipover device shown in FIG.7 including a portion of the V-belt conveyor showing the gaps thereinfor unloading the tiles from the setters;

FIG. 9 is an elevation view of the setter pusher/flipover device shownin FIG. 7; a

FIG. 10 is an enlarged perspective of the empty setter puller/turnerdevice;

FlG. lll is a plan view of the empty setter puller/turner device shownin FIG. 10;

FIG. 12 is an elevation view of the empty setter puller/turner deviceshown in FIG. 10; and

FIGS. 13-15 are schematic wiring diagrams of the electrical controlsystem used in the arrangement of FIG. 1.

Referring now to the drawings, and particularly to FIG. l, the preferredembodiment of the system includes a closed loop conveyor path comprisingfour conveyors 20, 22, 24!, and 26 arranged in a rectangular patternincluding a loading index conveyor or belt 20, an inching conveyor 22,an unloading index belt 24, and a V-belt conveyor 26. The loadingsurface 2?} of loading index belt 20 is positioned below thecorresponding surfaces of conveyors 22, 2d, and 26 for reasons to behereinafter described.

Ceramic tile squares from the presses and spray booths are emptied intoa pair of commercially available tile loading machines 30A and 31Apositioned adjacent the loading index belt 20. The particular type ordesign of loading index belt 20 is determined by the type of loadingmachines 30A and MA which are in use. Although the conveyor 20 describedherein is adapted to properly function with one type of loader, thesystem is flexible so as to merely require a slight modification toloading conveyor 20 to adapt the system to a different type of loader.

Setters 30 and 311 are alternately positioned on loading index belt 20and proceed along the belt until in a loading position where setter 3%is opposite loading machine 30A and setter 31 is opposite loadingmachine 31A. Each setter comprises a series of vertically spaced,horizontal slots arranged within a rectangular frame, and each slot issequentially filled with a green tile by the tile-loading machines WAand 31A in preparation for curing or firing in a kiln. The loadedsetters or saggers 30 and 31 then proceed down loading index belt 20 tothe end thereof adjacent the entrance end of inching conveyor 22.

A transfer device 3 then lifts a pair of setters 30 and 3t and transfersthem onto the surface 32 of conveyor 22. A series of photoelectric eyesor cells FEl through PEd are mounted adjacent the entrance end ofinching conveyor 22 and are selected in sequence by a Step Switch B tostop setters 39 and 3% at positions which form a course or layer. Thesetters advance one position at a time along the surface 32 of inchingconveyor 22, and upon the filling of the course or layer, theload/unload transfer carriage liiil is activated to descend and graspthe setters by means of a series of vacuum cups, elevating the settersslightly above the level of inching conveyor 22. Load/unload transferdevice 100 will be more specifically described hereinafter, however thecourse of setters is then transferred laterally to a position above anempty kiln car 36 positioned adjacent the entrance end of conveyor 22.The transfer carriage 100 descends and deposits a first layer of setterson the surface of kiln car 36 and returns to its home or waitingposition above the surface 32 of inching conveyor 22. The cycle is thenrepeated until the kiln car is loaded to a prescribed number of levels,whereupon kiln car 36 is dispatched to the kiln (not shown).

While the first pickup head 102 of transfer carriage 100 is loading kilncar 36, a second pickup head 104 at the opposite end of transfercarriage 100 is simultaneously unloading a kiln car 33 containingsetters with fired tiles, which has just returned from the kiln.Therefore, as the transfer carriage 100 returns from depositing a loadof setters on kiln car 36, it carries therewith a load of setters fromkiln car 38 to be deposited on the exit end of inching conveyor 22. Itis therefore apparent that transfer carriage 100 carries a load ofsetters during each lateral movement of the cycle, therefore eliminatingwasted motion.

The setters 30 and 31 proceed to the end of the inching conveyor wherethey are removed by a transfer device 40, similar to the transfer device34 positioned at the other end of inching conveyor 22, and placed on theunloading index belt 24 in an upright position. Transfers 34 and 40 areactually operated from the same source of vacuum and controlled by thesame latch relays L113 and LR6, and limit switches LS4 and LS5 to insurethat their transfers are made simultaneously. Unloading index belt 24extends perpendicular to inching conveyor 22 forming the third side ofthe closed loop system, therefore the setters move away from the inchingconveyor 22 at right angles thereto.

The setters proceed along unloading index belt 24 to the other endthereof, where a pair of setters 30 and 31 stop at a point adjacent thesetter pusher 200. A hydraulic cylinder 204 having the piston 206thereof connected to pusher plate 202 is then activated by relay LRS,whereupon the hydraulic cylinder 204 moves pusher plate 202 against thesetters pushing them over onto the horizontal platform 302 of a flipoverdevice 300. it should be pointed out here that the cylinders describedherein are specified as being preferably hydraulic, however pneumaticcylinders would also perform the function satisfactorily.

The flipover device 300 includes basically a horizontally disposedplatform 302 with a set of vertically disposed finger elements 304extending vertically from the side thereof opposite pusher plate 202,the assembly being pivoted about a horizontal axis adjacent the commonedge between platform 302 and fingers 304. A second hydraulic cylinder314 is operatively connected to the lower surface of platform 302, and,when setters 30 and 31 are moved onto the platform, tilts the platform90 so that the setters are turned over to a horizontal position on aV-belt conveyor assembly 26.

Conveyor 26 forms the fourth side of the system and is constructeddifferently than the other three conveyors in that gaps 42 and 44 areformed transversely across the surface of the conveyor belt, so thatwhen setters 30 pass thereover in a horizontal position, the individualtiles drop by gravity from the slots in setters 30 and 31 through gaps42 and 44, thus emptying the setters. The setters continue along V-beltconveyor 26 past a cleaning station 46 where the dust and lint is blownaway by air hoses.

As the setters approach the end of V-belt conveyor 26 they engage aseries of horizontally extending vacuum cups 402 forming part of setterturner 400. The suction is applied and the setters are pulled onto ahinged pan 404-, which then lowers the setters through a 90 arc anddeposits them in an upright position on the loading index belt 20. Thesuction is released and the setters 30 and 31 move perpendicularly awayfrom conveyor 26 on conveyor to be reloaded, and the setter turner 400returns to its normal position.

The setters have thus completed their trip around the entire closed loopsystem and are ready to be reloaded. The individual subcombinations ofthe load/unload transfer carriage 100, the setter pusher 200, theflipover device 300, the transfer device 400, and the electrical circuitwhich controls the system will be more thoroughly discussed below.

LOAD/UNLOAD TRANSFER CARRIAGE Turning now to FIGS. 26, the load/unloadtransfer carriage comprises a framework 102 overlying the major portionof inching conveyor 22 and the adjacent loading positions of kiln cars36 and 38. The framework 102 includes vertical support beams 104, 106,108, 110, 112, and 114 supporting an upper, horizontally disposed,rectangular frame 116 which in turn comprises generally front member118, rear channel 122, and side channels 120 and 124 fastened togetherand secured to the six vertical supports. intermediate channel 126extends between front channel 118 and rear channel 122 parallel to andapproximately midway between the side channels 120 and 124.

A transversely reciprocal carriage 128 includes wheels 130 which aresupported on the lower flanges of channels 120, 124 and 126 and adaptedto roll back and forth in a front-to-rear direction. Carriage 128supports and transversely reciprocates pickup heads 102 and 104 betweena position above kiln car 36 and inching conyeyor 32 and is operated bya double acting hydraulic cylinder 129, having the piston thereofattached to frame 116 and the housing thereof attached to carriage 128(see FIG. 6).

More specifically, carriage 128 comprises a central support beam 132 towhich hydraulic cylinder 134 is attached with the housing 136 ofcylinder 134 extending above support beam 132 and the operating piston138 extending through an opening 140 in central beam 132.

Pickup head 102 is suspended from the lower end of the hydraulic piston138 which operates to reciprocate pickup head 102 in a vertical path tolift and lower the courses of setters. Support beam 132 further includesa pair of openings 142, one on either side of opening 140 through whichsupport rods 144 and 146 are slidably received. The lower end of supportrods 144 and 146 are connected to the framework of pickup head 102, andoperate to prevent skewing of the pickup head during transfer.

Pickup head 102 itself comprises a rectangular horizontal framework 148attached to piston 138 and supporting a series of vacuum cups 150 whichengage setters 30 and 31 when pickup head 102 is lowered. A length offlexible tubing 15?. connects each vacuum cup 150 with one of severalvacuum conduits 154 supported by rectangular framework 148. A longersection of flexible tubing connects each vacuum conduit 154 with asource of suction 156 which in turn comprises essentially a motor 160driving a centrifugal pump 162. A portion of rectangular frame 116, forexample front member 116 is actually a hollow, longitudinal membersealed from the atmosphere and connected into the vacuum system toprovide a vacuum reservoir in case of a power failure or if the sourceof vacuum fails. This insures that the course of setters being held atthe time will not fall causing damage to the setters.

Pickup head 104 is identical to 102 as far as the mechanical parts areconcerned, and therefore the same element numbers will be used torepresent the details corresponding to pickup head 102. Thedistinguishing feature between pickup head 104 and 102 is that thepneumatic cycle of pickup head 104 is the reverse of pickup head 102, sothat when the vacuum is applied to the vacuum cups 150 of pickup head102 the vacuum is released from the suction cups of pickup head 104 andvice versa.

In operation, a kiln car 38 returns from the kiln loaded with severalcourses of setters containing fired tiles and is positioned adjacentinching conveyor 22 beneath pickup head 104. An empty kiln car 36 issimilarly positioned adjacent the other or head end of inching conveyor22 beneath pickup head 102. After a complete course of setters is loadedonto the initial end of inching conveyor 22, pickup carriage Mill isactivated by limit switch LSllZl. The pickup carriage Mill then descendsuntil vacuum cups 154) of pickup head 102 engage the top wall of setters3b and E51, whereupon the vacuum is applied to grasp the setters, andthe pickup head is elevated. During this operation the pickup head M4contains the last or lower course of setters from the previous kiln car33, and the vacuum is released to deposit them on inching conveyor 22 atthe same time the vacuum to pickup head 1192 is applied.

When a course of setters has been lifted and the pickup head i432reaches its upper extent, carriage 123 is activated by the advance ofstep switch A to traverse to a position where pickup head MP2 is aboveempty kiln car 36. Pickup head W2 is then activated by a further advanceof step switch A to descend whereupon the vacuum is released to depositthe course of setters onto kiln car 36, while pickup head 144 engagesthe top course of setters from loaded kiln car 3% and the vacuum appliedthereto. Pickup heads E02 and 104, through further advances of stepswitch A, are then elevated to their uppermost position and traverseback to a position overlying inching conveyor 22. When another course ofsetters is formed on the surface 32 of inching conveyor 22, the cycle isrepeated, and after every third cycle a new loaded kiln car is movedinto position beneath pickup head M4 by a standard under-car pusherdevice 37 and kiln car 3b which has become loaded is moved out and intothe kiln for firing.

SETTER PUSHER/FLIPOVER DEVICE The setter pusher 2110 and flipover device301) at the intersection or unloading index belt 24 and V-belt conveyor26, illustrated in FlGS. 7-9, comprise generally a hydraulicallyoperated ram plate 202 which reciprocates transversely across unloadingindex belt 24 for pushing a pair of setters 30 and 31 from the end ofbelt 24 onto a platform 3% of the tlipover device 3%. The flipoverdevice then rotates setters 31 and 31 onto their sides in a facedownarrangement atop V-belt conveyor 26 which carries the setters away andunloads them.

More specifically, setter pusher 2% comprises an upstanding support 2W,having the lower end thereof resting on the floor adjacent to theterminal end of unloading index belt 24. A second upstanding support 214is attached to one of the support sides of unloading index belt 24 andcombines with support 214 to provide a means for supporting a mountingframe 2%. Doubleacting hydraulic cylinder 2 84 is horizontally mountedatop frame 218 and includes a piston 2% with ram plate 24 2 attached tothe terminal end thereof. The setter-engaging surface of ram plate 2&2extends parallel with the direction in which unloading index belt 24 ismoving and the operation of cylinder 2ll4 pushes the plate 202transversely across belt 24 moving setters 3t and 31 positioned thereonover onto the flipover device Mill.

Flipover device sun comprises a support channel 310 suspended fromsupport beam 25 of unloading index belt 24 and connected at the lowerend thereof to support member 2149 by means of connecting bar 312. A lug316 extends horizontally from the lower end of support channel 310 andhydraulic cylinder 3l4 including reciprocal piston 318 is pivotallyattached thereto. An L-shaped setter bracket 326 comprises a normallyhorizontal platform 3132 extending transversely across the path ofsetters 3i) and 31 and a series of normally upstanding finger elements34104 attached to one transverse edge of support plate 302 whichsubstantially fills the gap between the end of V-belt conveyor 26 andunloading index belt 24. Support bracket 32b is mounted for rotationabout a transverse pin 322 suitably journaled to the framework of V-beltconveyor 26, adjacent the intersection between horizontal platform 362and vertical fingers 3W4. A lug 324 protrudes beneath horizontal supportplate 3432 and is pivotally connected to the terminal end of pistonElli.

So constructed, the setter pusher assembly Zlltl and the ilipover device3% operate in the following manner. When a pair of setters 3d and 31reach the terminal end of unloading index conveyor 24, and the entiresystem is ready to progress one step, hydraulic cylinder 2ll4 isactivated by latching relay LRE. This causes piston Zllti to urge ramplate 202 transversely across the end of unloading index conveyor 24carrying ahead of it setters 3d and 31 over onto the horizontal supportplatform 342 of flipover device 3%. Return of piston 2% to its normalposition engages a limit switch LSll which activates hydraulic cylinderl34 causing piston 31% to move upwardly, which in turn urges supportbracket 32% to rotate Fingers 344 are of such size that they fallbetween the belts forming V-belt conveyor 24, and upon the arcuatemovement mentioned above, lay setters Sill and 21 down upon their sideson the V-belt conveyor 26. Setters 3b and 31 then proceed along V-beltassembly 26, and the piston 318 of hydraulic cylinder 314 is reversedbringing the support platform 32% back up to the upright or home"position.

V-belt conveyor 26 further includes transverse slots or gaps 42 and 44across a portion of the belt, allowing the tiles to fall by gravity fromsetters 30 and 31 as they pass across the slots. The V-belt conveyor 26is just one example of several conveyors that could satisfactorily beused. Another example includes two separate conveyors, one of whichinitially receives the setters from flipover device 309 and moves slowlyto insure emptying of the setters 30 and 31. The second conveyor wouldcarry the empty setters toward the empty setter puller/turner 4M)considerably faster.

Setter cleaner 46 comprises merely one or more air hoses which blowcompressed air through the setters, thus cleaning the dirt and lint fromthem in preparation for reloading.

EMPTY SETTER TURNER As the setters 30 and 31 arrive at the end of thebelt conveyor 26 illustrated in FIGS. ill-12, the movement of theconveyor urges each setter into engagement with a pair of horizontallyarranged vacuum cups 462. Each vacuum cup 402 is attached to one end ofa horizontal tubular support rod designated as 4%, 4%, 4M), and 412, andthe vacuum applied to the other end thereof. A length of tubing 422extends from suction box 424 through support rod 4% to the vacuum cup atthe other end. A branch tube 426 likewise extends through support rod4%. The other pair of pull rods 411) and 412 receive branch tube 42% andtube 432 respectively, tube 432 being connected to suction box 434 whichin turn is connected to source of suction 436.

Horizontally reciprocal angle 444 and'stationary angle 405 retain thepull rods 4%, 4%, are and 412 in laterally spaced arrangement and arenormally longitudinally spaced from each other, with the piston 491 ofdouble acting hydraulic cylinder 4% being attached to the verticalflange of angle 404 and the housing 413 of the cylinder secured to angle405. As the hydraulic cylinder 4% is activated to retract piston 401,angle 444 and setters Bill and Ill are pulled toward angle 4% until thesetters are positioned over pan 433. Then as the fluid in cylinder 4% isreversed after releasing setters 30 and 3t, vacuum cups 402 return totheir normal position. Other flexible tubing 41$ and 417 connect asource of suction 419 with each end of hydraulic cylinder 403.

One transverse edge of hinged pan 428 is journaled between side rails44d and 442 of conveyor as in line with and irnmediately adjacent to theend of V-belt conveyor 26. Pan 438 is thus arranged for rotationalmovement between a horizontal position underlying setters 3d and 31 anda vertical position extending downwardly toward loading conveyor 24 Alug 444 extends downwardly from the under surface of pan 43b to whichthe free end of the piston 44% of double acting hydraulic cylinder 446is pivotally attached. A bracket 4% extends downwardly from the conveyorframework to pivotally attach the main housing of hydraulic cylinder 446thereto. Another length of flexible tubing 452 connects the hydrauliccylinder 446 with a pump 44"].

in operation, a pair of setters fill and Ill proceed to the end ofV-belt conveyor 2e, whereupon they engage one or more vacuum cups 402.Actuation of L81 signals the entire control system to advance one stepwhereupon latch relay LR4 activates the empty setter puller/turner andapplies suction from source 436 through pull rods 406, 408, 410, and 412thus grasping the setters. Hydraulic cylinder 403 is also energized topull setters 30 and 31 onto the surface of pan 438.

The hydraulic cylinder 446 is then activated by engagement of thesetters with limit switch L831 which lowers the pan 438 to a verticalposition, whereupon the setters are held some distance above the loadingindex conveyor 20. The hydraulic cylinder 403 is then reversed, loweringsetters 30 and 31 to a point immediately above the loading indexconveyor 20. The vacuum to vacuum cups 402 are then released, thesetters drop onto the surface of loading conveyor 20, and the pan 438 isreturned to its normal position. when another pair of setters 30 and 31engage the vacuum cups, the cycle is ready to be repeated.

ELECTRICAL OPERATION The present system is electrically controlled andhydraulically powered, the electrical controls. comprising generally asystem whereby a series of switches indicate or prove when eachapparatus is ready to proceed to the next step. At such a time as allproofs are met, the system automatically activates each station toadvance the entire machine one step.

In the test operation, the operator can manually actuate each apparatusseparately, however this is merely for purposes of test and setup andwill not be further discussed.

In the automatic operation, the machine is controlled by a pair ofprogrammer step switches, latch relays, control relays, limit switches,and pressure switches. Limit switch LS1 is located at the end of theloading index belt 20 which receives the filled setters 30 and 31 isoperated by the filled setters as they index forward. Limit switch LS1is the primary control limit switch that signals the entire system moveforward one position. Proofs L82, L86, L825, L820, L812, control relayCR6, L813, L832, CR2 and step switch A must indicate all functions havecompleted their previous operation and are at rest before the operationof limit switch L81 can advance the entire system. If the proofs aremet, the operation of limit switch L81 energizes time delay relay TDRlwhich in turn activates control relay CR4, whereupon the entire systemis activated to advance one step.

A series of photoelectric eyes, PEl-PE8, are mounted along the inchingconveyor to stop the setters being marshaled onto the inch belt at theproper point during each step. The photoelectric eyes are selected insequence by a step switch B which controls the marshaling onto and offof the inch belt. When the inching conveyor 22 becomes filled withsetters 30 and 31, limit switch L813 signals the pickup head 102 toremove the setters from the inching conveyor and place them on kiln car36.

Simultaneously, when limit switch L81 operates time delay relay TDR1 andcontrol relay CR4, then latch relay LR3 activates transfers 34 and 40 tolower them into engagement with a pair of setters for transfer. Whenlimit switch L84 indicates that the transfers 34 and 40 are inengagement with a pair of setters, the transfer vacuum is turned on bylatch relay LR6 and the vacuum cups are brought into contact with thesetters by a further position of limit switch L84. When the vacuum padsof transfer devices 34 and 40 have engaged the setters, and the vacuumhas been proven by vacuum switch V84, the transfer devices 34 and 40 areactivated to turn upward-lifting setters 30 and 31. Limit switch L85proves that the transfer devices 34 and 40 have completed their upturnand operates a control relay CR3, thus releasing latching relay LRo andlowering the transfer devices 34 and 40 to a position above one end ofinching conveyor 22 and one end of unloading index belt 24 respectively.Latch relay LR6 is then unlatched by control relay CR3, the vacuumreleased, and the transfer devices returned to their normal position.

At rest, the transfer carriage 128 is normally positioned over theinching conveyor 22, with pickup head 102 empty and pickup head 104full. At this time step switch A is in position 1. Limit switch L813 isengaged and operated when the inching conveyor 22 fills with green tile,activating both pickup heads 102 and 104 to bring them down to aposition immediately above the surface 32 of inching conveyor 22. Limitswitches L814 and L815 are engaged by the downward movement of pickupheads 102 and 104 respectively, and when both limit switches have beenengaged, the vacuum valve V83 shifts releasing the load of setters frompickup head 104 and placing vacuum on the vacuum heads of pickup head102. Control relay CR2 then activates both pickup heads 102 and 104 tolift them, whereupon limit switches L818 and L819 are engaged, advancingstep switch A to position 2, which energizes a traverse valve activatinghydraulic cylinder 129. Carriage 128 is then moved to a position overthe kiln cars 36 and 38, whereupon a limit switch L816 is engagedadvancing the step switch to position 3. Pickup heads 102 and 104 arethen lowered until limit switches L814 and L815 are engaged by pickupheads 102 and-104 respectively, whereupon the downward movement of thepickup heads is terminated. Vacuum switch 2 connected with pickup head104 then closes, gripping a course of setters from kiln car 38, andsimultaneously vacuum switch V81 releases the vacuum to pickup head 102dropping a course of setters onto kiln car 36. The pickup heads 102 and104 are then activated by control relay CR2, and lifted until limitswitches L818 and L819 are engaged, proving the hoists are up andadvancing step switch A to position 4. Control relay CR2 then releasesas the step switch advances, whereupon the traverse valve is energizedto return carriage 128 to "a position atop the inching conveyor 22, andlimit switch L817 is engaged, moving the step switch A to position 5.Pickup heads 102 and 104 then await a signal from limit switch L813which begins the cycle again. The transporting of the second course ofsetters occurs on steps 5, 6, 7, and 8 of step switch A, and on position9 the pickup heads 102 and 104 are waiting for the third course. Thetransporting of the third course occurs on positions 912 of step switchA, whereupon shifting of the kiln cars occurs. After the kiln cars aremoved and the proofs satisfied, step switch A resets to position 1 wherethe cycle begins again.

Upon completion of the loading of three courses of setters onto kiln car36 and the simultaneous unloading of three courses of setters from kilncar 38, step switch B signals the kiln car pusher 37 to index the carsforward by energizing latch relay LR2. While latch relay LR2 isenergized, the loading and unloading program of the cars cannot proceeduntil the cars are completely positioned. Upon a signal from latch relayLR2, the kiln car pusher 37 moves forward until it reaches limit switchL821, whereupon latch relay LRZ is released, and the car pusher returnedto its normal position-engaging limit switch L824. Limit switches L822and L823 are the proofs that the kiln cars are in position for anothercycle of loading and unloading of the kiln cars.

Operation of limit switch LS1, time delay relay TDRl and control relayCR4 also activate latch relay LRS, which energizes the double-actinghydraulic cylinder 204 to urge ram plate 202 across the end of unloadingindex belt 24, shifting a pair of setters 30 and 31 laterally onto theflipover device 400. Movement of ram plate 202 engages limit switch L810at the end of the stroke, releasing latch relay LRS, which reverseshydraulic cylinder 204 to return ram plate 202 to its normal position.As setters 30 and 31 are pushed onto flipover device 300, a limit switchL811 is engaged which operates to activate hydraulic cylinder 314,pushing the flipover device over to its second position, whereupon thesetters are resting on their sides on V-belt conveyor 26. As soon as theV-belt moves enough to carry setters 30 and 31 clear of the flipoverdevice, limit switch L811 and L833 release, bringing the flipover deviceback to its normal position, operating proof switch L825. The unloadingindex belt 24 then proceeds until another pair of setters engage limitswitch L820, signalling that the setters are in place on the unloadingindex belt 24.

1. A closed loop system for automatically handling open-side settersfilled with green ceramic tiles, loading them onto kiln cars for curing,unloading the setters from said cars upon their return from the kiln,emptying and cleaning the setters, and returning them to be reloadedwith tiles, said system comprising: a. a closed loop conveyor systemincluding a first loading conveyor, a second inching conveyor, a thirdunloading conveyor, and a fourth emptying conveyor; b. a loading machinealong said first conveyor adapted to fill a first group of said setterswith green ceramic tiles in preparation for delivery to said secondconveyor and subsequent curing in a kiln; c. a first transfer means totransfer said first group of setters from said first conveyor to saidsecond conveyor; d. a load/unload transfer means along said secondconveyor for loading said first group of setters from said secondconveyor onto one kiln car and unloading a second group of setters froma second kiln car onto said second conveyor for delivery to said thirdconveyor; e. a second transfer means to transfer said second group ofsetters from said second conveyor to said third conveyor; f. tiltingmeans positioned at the intersection of said third unloading conveyorand said fourth emptying conveyor for shifting said second group ofsetters onto said emptying conveyor and rotating said second group ofsetters about a horizontal axis to discharge their tiles; g. means forremoving said discharged tiles from said fourth conveyor; and h.resetting means positioned at the intersection of said fourth emptyingconveyor and said first loading conveyor for returning said setters toan upright position on said first conveyor.
 2. The closed loop systemaccording to claim 1 wherein said load/unload transfer means comprises acarriage mounted for reciprocal movement between a first positionoverlying said second inching conveyor and a second position overlyingkiln cars posiTioned adjacent said first conveyor means, a first andsecond pickup head mounted to said carriage at opposite ends thereof,each of said pickup heads being vertically reciprocal and including ameans for gripping and releasing a course of setters, said first pickupheads gripping a course of setters as the second pickup head releases acourse of setters and said second pickup head gripping a course ofsetters as said first pickup head releases, whereby said first pickuphead carries a course of setters from said inching conveyor onto anempty kiln car, and on the return trip said second pickup head carries acourse of setters from a loaded kiln car onto said second conveyormeans.
 3. The closed loop system according to claim 2 wherein saidtransfer carriage is activated in response to the forming of a completecourse of setters on the entrance end of said second inching conveyorbeneath said first pickup head.
 4. The closed loop system according toclaim 2 wherein each of said pickup heads further comprise a pluralityof suction cups adapted to engage said setters, each suction cup beingconnected to a source of suction, there being at least one suction cupper setter.
 5. The closed loop system according to claim 1 wherein saidfirst and second transfer means comprises a series of vacuum cupsmounted on a horizontal arm, said horizontal arm being pivotal around ahorizontal axis extending transversely of said second inching conveyor,said vacuum cups being connected to a source of suction whereby whensaid cups engage the upper wall of said setters, said setters may belifted from one of said conveyors to another adjacent conveyor.
 6. Theclosed loop system according to claim 1 wherein said tilting meanscomprises a ram plate and a flipover device, said ram plate beingreciprocal between a position on one side of said third unloadingconveyor and a second position on the other side of said conveyoradjacent said flipover device, comprising a normally horizontal supportplate onto which said setters are shifted by said ram plate, saidsupport plate being rotatable between a first horizontal position and asecond position arcuately spaced 90* from said first position, wherebysaid ram plate pushes a pair of setters from said second conveying meansonto the support plate of said flipover device and said flipover deviceturns said setters 90* from an upright position to a position where saidsetters are horizontally disposed.
 7. The closed loop system accordingto claim 6 wherein said ram plate is connected to the piston of ahydraulic cylinder for operating said plate between said first andsecond position.
 8. The closed loop system according to claim 6 whereinsaid flipover device comprises a series of fingers normally disposedperpendicular to said support plate to provide support during thetilting of said setters, said support plate being attached to ahydraulic cylinder and operated thereby.
 9. The closed loop systemaccording to claim 1 wherein said means for removing said dischargedtiles from said fourth emptying conveyor includes at least one gaptherein through which the tiles in said setters drop by gravity as thesetters proceed along said conveyor.
 10. The closed loop systemaccording to claim 1 wherein said fourth emptying conveyor furtherincludes a cleaning means, whereby said setters are cleaned inpreparation for reloading.
 11. The closed loop system according to claim1 wherein said resetting means comprises a series of vacuum cupshorizontally arranged in the plane of said emptying conveyor and againstwhich the incoming setters are urged, said vacuum cups being connectedto a source of suction and being activated in response to engagement ofsaid vacuum cups with the upper wall of said setters, means for rotatingsaid vacuum cups to a vertical position, whereby said setters are movedfrom a horizontal position on said fourth emptying conveyor to anupright position on said first loading conveyor.
 12. The closed loopsystem according to claim 11 wherein said means for rotating said vacuumcups to a vertical position comprises a double-acting hydrauliccylinder.
 13. The closed loop conveyor according to claim 11 whereinsaid vacuum cups are horizontally reciprocal between a normally extendedposition and a retracted position, a hinged pan underlying said vacuumcups in said retracted position, said pan providing support for saidsetters during the pivotal movement of the setters to an uprightposition.
 14. The closed loop system according to claim 11 wherein saidfirst loading conveyor is vertically spaced below the level of saidsecond and fourth conveyors.
 15. The closed loop system according toclaim 14 wherein the space between said first conveyor belt and saidother conveyor means is greater than the height of a setter.